Afghan Bestway Transportation

SMALL CEMENT PLANT

100 TONS/DAY
PRELIMINARY REPORT

Prepared by:
Engr. KAMRAN RUSTAM

Clinker production : 100 tones/day

Number of vertical shaft kilns : 1 Nos
Capacity of one kiln 100 tones/day
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Layout for 100 Tons Small Cement Plant

BLOCK DIAGRAM

Block diagram of 100 tons/day cement manufacturing

Limestone Storage Yard Raw Mill Feed Area

Crusher Machine Operations of EP & C Tower
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Coal Mill
Kiln SILO
Coal Mill Feed Area
Kiln Motor Preheater & Porcelain

Silo
Clinker Silo Cement Mill Feed Area
Cement Mill
EP cooler Gypsum Crusher

Packing Plant

POWER PLANT:
For continuous and smooth operations of the plant uninterrupted power supply is very crucial. The company

has its own power generation plant along with WAPDA supply. The Company power plant consists of one

Generators, which is dual nature generators that can be run on GAS as well as on Diesel depends upon
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availability of fuel. In case if any of supporting engine fails to work the company has Turbine Engine of

CATERPILLARS so that there is no load shedding at all. The generator combines produce 1.2MV of energy

QUARRY and LIMESTONES CRUSHER:

QUARRY
Quarry is the place from where raw material in extracted. Drilling and blasting is done to extract the material.

A hole of about 10-15 m is drilled and ammonium nitrate in filled as an explosive in these holes. When this

explosive is ignited the rocks are broken into pieces of different sizes. These pieces are then loaded on the

dumper trucks and using conveyor belt to the crusher. It is located about 300 meters from the plant crusher.

The motors that are used for moving the conveyor belt are INDUCTION motors of 2 Kw of power.

RAW MATERIALS
95% of limestone is used for the making of cement at plant. This limestone is extracted by nearby Quarry
and has the highest composition in cement.

Additive Materials
The additive materials that are mixed with limestone at raw mill feed area
areC LA Y,IRO N,BA UX IT ES and SILLICA SAND.
Gypsum
The remaining 5% of material is gypsum which is mixed with
Klinker material at cement mill and be ready for paking plant.

1 Introduction
"Small Cement Plant" (SCP) producing quantity of 100 tons/day
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Process
Mined limestone is reduced to < 25 mm in size in the crushing section. Crushed raw
materials are then extracted along with fuel and fed to mill in the right proportion.
In the Raw mill these materials are ground to powder and then blended in a
pneumatic blending system. The raw meal powder is then nodulised by spraying
water in a nodulising drum. The nodules are then fed to the kiln and burned to
clinker.

The clinker and Gypsum are stored in a storage yard. Clinker is allowed to naturally
cool for 15 days. Clinker along with a small per cent of Gypsum is ground in to
cement in the Cement mill. The cement is stored in a RCC Silo. As and when required
this cement is extracted from silo and packed in to 50 kgs bags and despatched by
truck or train to the customers

Limestone 11

Crusher 2

Grinder 3
Raw Meal 4
Kiln 5

Additives
Additives 7
7
Klinker
Klinker 6
6
Grinder
Grinder 8
8

Cement

Advantages of Small Cement Plants

Small cement plants offer some specific technical and economic advantages in given
situations.
These include:
• Lower capital investment per unit of production without sacrificing the quality
of the product;
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• Lower gestation period which helps in realizing quicker returns on capital

invested;
• Bringing cement manufacture within the financial capacity of the smaller
entrepreneur;
• Creating employment opportunities in rural areas;
• Setting up a cement industry in locations where movement of heavy machinery
is difficult;
• Exploitation of small deposits of limestone as well as limited quantities of
calcareous industrial wastes;
• Reducing the average unit cost
of transporting cement
through the dispersal of
cement-production facilities.

Vertical Shaft Kiln

In the black-meal process of the
clinkerization based on VSK
technology, the low-volatile fuel,
i.e., coke-breeze or saleable low-
volatile (SLV) coal, is uniformly
mixed with raw materials during
grinding and is fed into the vertical-
shaft kiln from the top in the form
of nodules of 5-10 mm diameter.

Technical Specification Of VSK

Capacity 70m3
Diameter 3600mm
Height 15000mm
Height of Legs 6000mm
Diameter of Silo 4000mm The entire space of the kiln is filled with
nodules. Air required for burning the
clinker enters from the bottom of the kiln and moves upwards through the voids and
gaps in the burnt clinker. The clinker is cooled rapidly and the air is preheated. Fuel
particles of the raw-meal nodules bum, when the preheated air is in contact with
them. The cooled clinker will be discharged out of the kiln from its bottom. Good
operation of the kiln aims at high productivity with improved clinker quality and low
fuel and material composition, and fuel consumption, taking into consideration the
structure of the kiln, and condition of air ventilation through the nodule/clinker bed.
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QUALITY CONTROL REQUIREMENT

The essential components that constitute the raw meal feed for cement-making are
calcium carbonate, aluminium silicates, iron and aluminium oxides and some minor
constituents. Of these, the first three are important in the formation of cement
clinker, while the fourth affects the manufacturing process and clinker-phase
formation depending upon the type and quantity of minor constituents. The quality
prerequisites of raw materials and fuels for the different processes of small cement
plants. The main guidelines determining the suitability of various raw materials for
manufacture of Portland cement through VSK technology are given in the following
paragraphs.There are several factors influencing the quality, quantity and the
production cost of cement, and therefore, depending upon the manufacturing process
and the equipment used or on the actual situations of use, specific control points are
located. Data are collected at various control points at desired frequencies, analysed
and corrective steps are taken to maintain consistency in, and the desired level of
quality of the product.
SECTION-WISE CAPACITIES

RAW MATERIAL REQUIREMENT

Major raw materials used in cement manufacture are Limestone and Clay. If all the
chemical components required are not available in these two, additive materials will
be used to compensate.

RAW MILL SECTION

Raw meal required 100 tons/day
Weekly requirement : 700 tones/week
Working hours/week 168 hours
Mill capacity 4.15 tones/h

Raw-mix design
The chemical composition of Portland-cement clinker is made up of several oxide
components of which some are desirable and others are tolerated because they are
unavoidable, though unwanted.

Even in the case of desirable oxides, the relative proportions have to be optimized in
such a way that a trouble-free and smooth operation of the plant is ensured,
production efficiency and fuel economy are maximized, the quality of the product
satisfies all the requirements and at the same time the cost of production is
minimized.
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RAW MILL SECTION

Based on practical experience gained over several decades and also on research
investigations, the relative proportions of major constituent oxides which will
facilitate production and also ensure a reasonable degree of performance have been
defined in modulii values; An increasing silica modulus impairs the burn ability by
reducing the liquid phase content, causes slow setting, hardening and also dusting in
the kiln. The alumina modulus determines the composition of the liquid phase in
clinker. The lower the ratio, the harder is the burning. A higher ratio gives rise to
lumping of clinker, high heat of hydration and fast setting. The preferred values of
LSF are in the range of 0.85 to 0.95. With LSF below the lower limit one can expect a
predominance of dicalcium silicate (belite) with a lower temperature of burning,
while an LSF exceeding the upper limit is expected to require a high burning zone
temperature. Normally used additive materials are Bauxite, Laterite and Sand stone.
Coke breeze is the fuel generally used in SCP plants. Gypsum is ground along with
clinker to produce Ordinary Portland Cement.

The life of a cement plant should be about 30 years for it to be a viable unit.
Therefore, raw materials also should be available nearby for that period. About 80%
of the material used in cement production is Limestone and this should be available
nearby for the life of the plant. Clay also is required for cement production and
usually this material is available closely. Gypsum and fuel are the other
requirements. These are to be brought from reliable sources and kept in stock for
three to four months. While oil or coal can be used as fuel in a rotary kiln plant, fuel
is limited to coke or de-volatilised coal in the case of vertical shaft kilns.

Block Diagram
Cao > 48%
Mgo > 35%
SiO2 > 8% Clay < 200mm
Fe203
Limestone > 300mm Jaw Crusher <300mm Impactor < 20mm Storage Yard
Limestone Deposit
950 – 100 kg/cm2
Indicted reserver Additive < 200mm
1.8 million

Burning Blending & Storage < 90micron 90micron Raw Mill < 20mm
feeder

Crusher <20mm Clinker Storage Cement Mill

Packer
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MAJOR ELEMENTS FOR CEMENT PRDUCTION

LIMESTONE:
Limestone is a very strong rock and is often cut into large blocks and used in the
construction of buildings and skyscrapers.

Crushed limestone is also used to make cement, plaster and chalk. Limestone fizzes
in vinegar, which means that it reacts to acids. This also means that the outsides of
many of our buildings and monuments are being affected by acid rain. Acid rain
occurs when large companies pollute the air by releasing chemicals like sulphur into
the atmosphere. The sulphur combines with hydrogen and oxygen in the air to form
sulphuric acid! Chalk is also a type of Limestone.

LIMESTONE REQUIREMENT
Daily requirement : 80 tones/day
Monthly requirement 2400 tones/month

Chemical Composition of Limestone for 100TPD

CaO : > 48%
MgO : < 3.5%
SiO2 : < 8%
Al2O3 : to satisfy LSF & SM in raw mix
Fe2O3 : to satisfy LSF & SM in raw mix
Crushing strength : 950-1000 kgf/cm2
Limestone deposit : 1.8 million of indicated reserve
2.7 million of inferred reserve
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CLAY
The interaction of cement with clay or clay with cement
and the stability of both materials is of special interest in
many cases of environmental concern. Possible interactions
of these materials happen in waste deposits of various
kinds. Clay-cement suspensions are used in slurry walls for
remediation of hazardous waste sites. Here the high pH
may cause a destabilization of certain clay minerals and
also a decrease in the clay-concrete strength compared to
clay-free concretes.
The setting of the cement has been showed to be strongly influenced by the kind of clay
used in the suspension. The interaction of settled cement and clay is of interest in cases
where for example a clay barrier is built in connection with existing concrete constructions
in a waste disposal. For a better understanding of the clay cement reactions compacted
mixtures of setted finely grinded cement or calcium hydroxide were examined after being
allowed to swell under constant volume condition at elevated temperatures for 4 to 16
weeks. The interface of setted cement and Na- and Ca-bentonite was investigated in
relevance to changes in mineralogy and microstructure.

CLAY REQUIREMENT
Daily requirement : 17.5 tones/day
Monthly requirement : 525 tones/month

The most obvious reaction is the replacement of exchangeable sodium ions in the Na-
bentonite with calcium ions from the cement pore water. However, results also indicate a
beginning structural alteration of the Montmorillonite. In this case leaching of alumina from
the octahedral sheet produces a silica-rich residual phase (possibly Cristobalite) and a tetra-
calcium-alumina-hydrate (4CaO Al2O3 13H2O)

COKE BREEZE
Raw meal interground with fuel (called “black meal”) is fed in the form of nodules. Because of this, there
is an inherent limitation on the maximum volatile matter of the fuel. The volatile matter should not
exceed 10 per cent, otherwise during burning the intranodule pressure may increase due to the release of
the volatile matter. Consequently the nodules may break. Coke-breeze, a waste product from the steel
industry, has so far been used as fuel in VSK cement plants. The preferable specification of coke-breeze
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or any other fuel for the VSK process is as follows:

COKE BREEZE REQUIREMENT

Daily requirement : 17.5 tones/day
Monthly requirement : 525 tones/month

Chemical Composition
Ash : 25-25 per cent
Volatile matter : below 10 per cent
Calorific value : 4500 kcal/kg or more

However, the considerable growth of VSK-based mini-cement plants all over India and the dwindling
availability of coke-breeze due to the recent recycling of coke-breeze by the steel industry has
created the need to identify various alternative fuels and to establish their suitability firmly through
plant trials.

GYPSUM
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Gypsum is a very soft mineral composed of calcium sulfate dihydrate, with the chemical formula
CaSO4·2H2O

DAILY REQUIREMENT
Daily requirement 5 tones/day
Monthly requirement 150 tones/month
No. of VSKs : 1 nos.
Capacity of each VSK : 100 tones/day of clinker

OTHER CUNSUMABLE ELEMENTS

ADDITIVE REQUIREMENT
Daily requirement : 2.5 tones/day
Monthly requirement : 75 tones/month

STORAGE REQUIRMENT
Clinker stock : 1500 tones
Gypsum stock : 450 tones

BLENDING
Capacity of one blending silo 52.5 tones
No. of blending silos 1 nos
Storage capacity 148.6 cu.m
Silo diameter same as cement silo
No. of storage silos 1 no.
CRUSHING SECTION
Weekly Limestone Tons/hour
requirements : 945
Weekly requirement 735 tones/week
Working hours 49 hours/week
Capacity of packer 15 tones/h
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STOCK Tons
Limestone stock 4050
Clay stock 525
Coke breeze stock 1575
Additive stock 450

POWER
In a SCP, daily power requirements are relatively less compared to the large cement plant. A
one million tones/annum plant will consume about 3.3 million units of electricity a day
compared to that of 100,000 tones/annum SCP at 0.033 million units/day.
Power KWH/ton
Units/tone (avg) 1200
Units reqd /year 438,000

WATER SUPPLY
Water is required in a cement plant for human consumption, cleaning purposes, cooling of
equipment and for nodulising in SCP plants. Taking an average of 250 litres/tone of cement
produced, we need about 75,000 litres of water/day for a 100,000 tpa cement unit. This is
far less than the 350,000 litres needed for a one million tones/annum plant.

Water Litre
For Process 26,000
For human Consumption 5000
Mill cooling & make-up 9000
40,000

ENVIRONMENTAL CONTROL IN CEMENT

PLANTS
1 Introduction
Environmental control aspects are being given increasing importance in recent years.
Of the two aspects of immediate concern, viz, water and air pollution, SCP cement
plants are free of water pollution completely as there is no effluent production. Even
in the case of air pollution, which can be caused by dust and undesirable gases,
Vertical Shaft Kiln (SCP) emits negligible amounts as to cause serious health
concerns. The small amounts of Nitrous oxide and Carbon monoxide emissions are the
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result of unsatisfactory burning in the kiln during initial stages which will subside
once the operators get more experience in the burning techniques. Dust generation,
though negligible, is inherent in the burning process and better burning techniques
reduce the emission levels considerably. In the following paragraphs of this report,
we give the dust generation sources, their characteristics and the methods presently
employed to limit dust emission are detailed.

3 Dust Generation sources and characteristics

3.1 Mining
Manual mining is employed in SCP cement plants and dust generation is low.
However, sometimes free dust is generated while drilling and this is suppressed using
water sprays.

3.2 Crushing
Main dust generation source is the Secondary Crusher and a Bag filter system is
provided to collect and remove this dust.

3.3 Raw Mill

While grinding the raw materials in the Ball mill, some dust is produced. This is
collected in Cyclones and bag Filters.

3.4 Blending & Storing

Dust generated during this process is collected in Bag filters and fed back in to the
storage silo.

3.5 Kiln section

The kiln feed is in the form of moist nodules and do not generate dust. This bed
ensures that dust entrained in the lower portions of the kiln is filtered during its
upward movement.
Kiln chimneys operate under natural drafts and do not generate any dust emission.
The low velocity of gas in the c himney allows the dust to settle. Movers (India) have
provided a Wet Scrubber at the chimney which ensures further that whatever dust
generated in the kiln is entrapped in the water spray of the scrubber. The slurry
formed is fed back in to the Noduliser.

3.6 Cement grinding

Cement mill is provided with bag filter to collect the dust generated during grinding.

3.7 Storage and Packing

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For the storage silo as well as the packer, bag filter is provided to collect the dust
generated.

DUST GENERATION
Measured/Calculated Quantity
Exhaust
gases 2.42 Nm3/kg of clinker
CO 2000 mg/m3 at 80 deg.C
SO2 80 mg/m3 at 80 deg.C
Dust content 400 mg/m3 at 80 deg.C

Process involving burning

SO2 < 2000 mg/1000000 kcal (for coke as fuel)
Dust <120 mg/1000000 kcal (for coke as fuel)

Dust emission < 100 mg/m3